Vehicle seat

ABSTRACT

A vehicle seat comprises: a base frame (side frame  4 , pipe frame  5 ) which constitutes at least left and right lower portions of a seat back frame; a force-receiving member (bracket  7 ) disposed adjacent to a left or right outer side of the base frame, and configured to receive a load from outside in a lateral direction; and a load transmission part configured to transmit the load from the force-receiving member to a side laterally opposite to that on which the force-receiving member is provided, wherein the force-receiving member has a shape with a closed cross section, and a portion of at least one of an upper wall ( 72 ) and a lower wall ( 74 ) separate from front and rear ends thereof provides an uneven shape (stepped profile  72   a,    74   a ).

TECHNICAL FIELD

The present invention relates to a vehicle seat in which a side collision load on a vehicle can be transmitted laterally from outside toward inside.

BACKGROUND ART

A vehicle seat comprising a pipe frame (inner frame) shaped like a rectangular loop, a plate-like side frame disposed adjacent to a left or right outer side of the pipe frame, and a bracket (force-receiving member) fixed to a left or right outer side of the side frame has hitherto been known in the art (see JP 2000-103275 A). In this technique, the bracket is shaped like a box having front, rear, upper and lower sides all of which are flat, and when a side collision load imposed on the vehicle is received by the bracket from outside in a lateral direction, this side collision load is transmitted through the respective flat surfaces inward in the lateral direction.

However, with the conventional technique, since the sides of the bracket for transmitting a side collision load are flat, these flat sides of bracket, if their wall thickness is thin, would be buckled upon receipt of a side collision load, with the result that the load disadvantageously could not properly be transmitted inward in the lateral direction.

Against this backdrop, the inventors named in the present application have created the present invention in an effort to provide a vehicle seat in which a load can be properly transmitted laterally from outside toward inside even if the wall thickness of the bracket (force-receiving member) is thin.

SUMMARY OF INVENTION

Specifically, a vehicle seat according to one aspect of the present invention comprises: a base frame which constitutes at least left and right lower portions of a seat back frame; a force-receiving member disposed adjacent to a left or right outer side of the base frame, and configured to receive a load from outside in a lateral direction; and a load transmission part configured to transmit the load from the force-receiving member to a side laterally opposite to that on which the force-receiving member is provided. The force-receiving member includes an upper wall and a lower wall and has a shape with a closed cross section, and a portion of at least one of the upper wall and the lower wall separate from front and rear ends thereof provides an uneven shape.

With this configuration, since at least one of the upper and lower walls of the force-receiving member has a portion separate from the front and rear ends thereof which portion has an uneven shape, the rigidity of that portion of the wall(s) having the uneven shape is thus increased, so that the wall(s) can be prevented from being buckled even if the wall thickness of the force-receiving member is thin; therefore, the load received from laterally outside toward inside can be transmitted effectively. In addition, since the uneven shape is not provided on the front and rear ends of the upper wall and the lower wall, the front end and rear end corners of the upper wall and the lower wall can be formed continuously in the lateral direction, so that these continuous corners can effectively transmit the load from outside to inside in the lateral direction.

In the above-described configuration, the uneven shape may be of a stepped profile formed by overlapping two plate-like portions.

With this feature, since the overlapped portion of the two plate-like portions is rendered thicker, the rigidity can be enhanced.

Moreover, the stepped profile may be continuously formed from the at least one of the upper wall and the lower wall to an outer wall located at a laterally outer side of the force-receiving member.

With this feature, since the thicker portion is continuously formed from the outer wall to the upper wall or the lower wall, a load received at the outer wall can be effectively transmitted to the upper wall or the lower wall.

Furthermore, the force-receiving member may be segmented in front and rear halves of box-like members which are fitted together, and configured such that the stepped profile is formed as a result of fitting the box-like members together, continuously across the upper wall, the outer wall and the lower wall.

With this feature, since the thicker portion of the outer wall extends continuously to the upper wall and the lower wall, a load received at the outer wall can be transmitted effectively through the upper wall and the lower wall in a laterally inward direction.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a vehicle seat according to one embodiment of the present invention;

FIG. 2 is an enlarged perspective view of a bracket and its surrounding structure as viewed from the front;

FIG. 3 shows (a) section I-I, (b) section II-II, and (c) section of FIG. 2;

FIG. 4 is an enlarged perspective view of the bracket and its surrounding structure as viewed from the rear; and

FIG. 5 includes (a) a perspective view showing an embodiment having a stepped profile formed only on an upper wall, and (b) a perspective view showing an embodiment having a stepped profile formed continuously only on the upper wall and an outer wall.

MODE(S) FOR CARRYING OUT THE INVENTION

Hereafter, a description will be given of one embodiment of the present invention with reference to the drawings.

A vehicle seat according to the present invention is made up of a seat frame 1 as shown in FIG. 1 the outside of which is covered with a seat cushion made of urethane foam or the like. The seat frame 1 includes a seat back frame 2 and a seat bottom frame 3. It is to be understood that in describing the present invention, the front/rear, left/right and upper/lower are defined as viewed from an occupant sitting on the seat.

The seat back frame 2 is configured to include a pair of side frames 4 and a pipe frame 5 as one example of a base frame, a lower frame 6 as one example of a load transmission part, and a bracket 7 as one example of a force-receiving member.

The side frames 4 are plate-like members which constitute left and right lower portions of the seat back frame 2, and each configured to protrude frontward (in at least one of the front and rear directions) beyond the pipe frame 5, as shown in FIG. 2. This configuration provides a frontwardly overhanging shape formed at each side of the seat back, and allows an air bag or other parts to be securely fixed to the frontwardly and rearwardly extending plate-like side frames 4.

To be more specific, as shown in FIG. 3( a), each side frame 4 has a through hole 41 pierced through the left and right sides at an appropriate position thereof, and a front portion 42 thereof is bent inwardly to the left or to the right and further bent to the rear to form a U-shaped cross section. This configuration serves to improve the rigidity of the front portion 42 of the side frame 4.

A rear portion 43 of each side frame 4 is bent inwardly to the left or to the right to form an L-shaped cross section, and is joined to the pipe frame 5 by welding. In FIG. 3( a), welds or spots welded by a welding torch T are illustrated with exaggerated black dots.

As shown in FIG. 1, the pipe frame 5 is a reinforcing frame for reinforcing the side frame 4, having a cylindrical shape (with a closed section), which is bent into a shape of a substantially rectangular loop. Left and right lower portions of the pipe frame 5 are disposed adjacent, and joined, to laterally inner sides of the side frames 4, respectively. With this configuration, a lower portion 51 (including portions extending obliquely downward from the portions adjacent to the side frames 4) of the pipe frame 5 is configured to serve, in combination with the lower frame 6, as a load transmission part, to transmit a load to the left or to the right.

Two wires W bent to ascend and descend several times are provided in positions spaced out vertically, and joined to left and right side portions 52, 53 of the pipe frame 5, and a pressure-receiving member C shaped like a plate and made of plastic are fixed to these wires W. With this configuration, when the vehicle receives a rear-end collision load, the occupant subsides rearward together with the receiving member C inside the pipe frame 5, and thus the impact of the rear-end collision load against the occupant can be softened.

The lower frame 6 is a plate-like member extending laterally, which is joined to the lower portions of the side frames 4 and to the lower portion 51 of the pipe frame 5. With this configuration, a load imposed on the bracket 7 from outside in the left or right direction is transmitted through the lower frame 6 and the lower portion 51 of the pipe frame 5 to the side laterally opposite to that on which the bracket 7 is provided.

The bracket 7 is a part provided discretely from the pipe frame 5 and the side frames 4, and disposed adjacent, and joined, to the left side (laterally outer side) of the left side frame 4 (one of the side frames 4). To be more specific, the bracket 7 is disposed near a side panel such as a side pillar or a door of the vehicle, so that a side collision load imposed on the vehicle is received thereby.

The bracket 7 is, as shown in FIG. 2, directly fixed by welding to the pipe frame 5 through two through holes 41 (opening) formed in the side frame 4. With this configuration, irrespective of the angle and magnitude of the side collision load received, the load can be transmitted properly from the bracket 7 to the pipe frame 5 without getting affected by deformation of the side frame 4. In FIG. 2 and FIG. 4, the welded spots are illustrated with shades of dots.

To be more specific, the bracket 7 is segmented in front and rear halves of a front-side box-like member 8 and a rear-side box-like member 9 which are fitted together, and configured such that the box-like members 8, 9, once combined together, form a closed section as taken along a plane perpendicular to the lateral direction.

The front-side box-like member 8 includes a plate-like front wall 81 elongated in the upward-and-downward direction longer than extending in the lateral direction, an upper wall 82 extending from an upper end of the front wall 81 rearward, an outer wall 83 extending from a laterally outer end of the front wall 81 rearward, and a lower wall 84 extending from a lower end of the front wall 81 rearward, all of which are provided integrally. In other words, the front-side box-like member 8 is configured to have a shape of a box which opens to the rear and to a laterally inner side.

In the front wall 81, two recessed portions 81 a (providing an uneven shape) disposed in a portion separate from upper and lower ends of the front wall 81 and configured to be recessed inwardly in the front-rear direction are arranged in positions spaced out vertically at a predetermined distance. With this configuration, the rigidity of the front wall 81 is enhanced, and thus a side collision load can be transmitted effectively to the pipe frame 5 by the high-rigidity front wall 81. Moreover, since the recessed portions 81 a are formed in the portion of the front wall 81 separate from the upper and lower ends thereof, the upper and lower end corners of the front wall 81 can be formed continuously in the left-right direction, so that the continuous corners can effectively transmit the load from outside to inside in the lateral direction.

Each recessed portion 81 a is formed at a laterally inner end portion 81 b of the front wall 81, and thus opens to the front and to the laterally inner side. With this configuration, an edge 81 c of the end portion 81 b is bent to the front and to the rear, and thus the rigidity of the edge 81 c located at an output side of the side collision load can be increased, so that the side collision load can effectively be transmitted to the pipe frame 5 or the like.

Each recessed portion 81 a has a bottom wall 81 d, at which an extension portion 81 e (part of the force-receiving member provided at a laterally inner side thereof) extending laterally inward beyond the edge 81 c of the front wall 81 is formed. This extension portion 81 e is disposed inside the through hole 41 of the side frame 4 described above, and extends to the pipe frame 5, so that the extension portion 81 e abutting on the pipe frame 5 is welded to the pipe frame 5.

Since only the extension portion 81 e is passed through the through hole 41, the through hole 41 may be sized to conform to the extension portion 81 e, and thus the through hole 41 may be made smaller so that the rigidity of the side frame 4 can be enhanced. To be more specific, in the present embodiment, the through hole 41 is shaped like an elongate hole having dimensions smaller than the width of the pipe frame 5 in a front-rear direction, and smaller than the whole length of the edge 81 c of the front wall 81 and greater than the extension portion 81 e in a vertical direction.

The size of the through hole 41 may be designed to have, at the largest, an area comparable or smaller than a cross-sectional area of a laterally inner end portion (adjacent an end located at a side from which the side collision load is outputted) of the bracket 7. The through hole 41 formed to have a size described above makes it possible to impart a higher rigidity of the side frame 4, for example, in comparison with a through hole formed in the side frame to have such a size as to allow the laterally inner end portion of the bracket 7 to be passed through in its entirety.

Although the extension portion 81 e is provided in the present embodiment, the present invention is not limited to this configuration; i.e., a configuration without the extension portion 81 e may also be possible. In this configuration, some gap may be left between the pipe frame 5 and the edge 81 c of the front wall 81, but this gap still permits welding by which the pipe frame 5 and the bracket can be joined directly.

The extension portion 81 e is, as shown in FIG. 3( a), fixed to a central portion 5 a located at a center in the front-rear direction of the pipe frame 5. With this configuration, the load from the bracket 7 is transmitted intensively to the central portion 5 a of the pipe frame 5, and thus the load can be transmitted more effectively.

A center 5 b in the front-rear direction of the pipe frame 5 is located within a width in the front-rear direction of the bracket 7. With this configuration, upon side collision, the load can be transmitted more effectively because the bracket 7 can be prevented from slipping out to the front or to the rear on a cylindrical outer surface of the pipe frame 5.

As shown in FIG. 2, an upper portion and a lower portion of the edge 81 c of the front wall 81 are fixed to the side frame 4 by welding. In other words, the front wall 81 is fixed directly to both of the side frame 4 and the pipe frame 5. With this configuration, the load received by the bracket 7 is transmitted not only through the pipe frame 5 but also through the side frame 4 to the load transmission part (the lower frame 6 and the lower portion 51 of the pipe frame 5), and thus more effective transmission of the load can be ensured. It is appreciated that the load transmitted to the load transmission part can be transmitted to the vehicle body side through a console box or the like provided at a side opposite to that on which the bracket 7 is provided.

As shown in FIG. 4, the rear-side box-like member 9 includes a plate-like rear wall 91 elongated in the upward-and-downward direction longer than extending in the lateral direction, an upper wall 92 extending from an upper end of the rear wall 91 frontward, an outer wall 93 extending from a laterally outer end of the rear wall 91 frontward, and a lower wall 94 extending from a lower end of the rear wall 91 frontward, all of which are provided integrally. In short, the rear-side box-like member 9 is configured to have a shape of a box which opens to the front and to the laterally inner side.

In the rear wall 91, two recessed portions 91 a (providing an uneven shape) disposed in a portion separate from upper and lower ends of the rear wall 91 and configured to be recessed inwardly in the front-rear direction are arranged in positions spaced out vertically at a predetermined distance. With this configuration, the rigidity of the rear wall 91 is enhanced, and thus a side collision load can be transmitted effectively to the laterally inner side by the high-rigidity rear wall 91. Moreover, since the recessed portions 91 a are formed in the portion of the rear wall 91 separate from the upper and lower ends thereof, the upper and lower end corners of the rear wall 91 can be formed continuously in the left-right direction, so that the continuous corners can effectively transmit the load from outside to inside in the lateral direction.

Each recessed 91 a is disposed opposite to a corresponding recessed portion 81 a of the front-side box-like member 8 in the front-rear direction, whereas each bottom wall 91 d and a bottom wall 81 d of a corresponding recessed portion 81 a are disposed to adjoin to each other, as shown in FIG. 3( a). With this configuration, the two bottom walls 81 d, 91 d adjoining to each other constitute a thick portion located substantially at the center in the front-rear direction, and thus effective transmission of the side collision load can be achieved.

The two bottom walls 81 d, 91 d adjoining to each other are joined together by welding. With this configuration, the rigidity of the bracket 7 can be enhanced, and thus effective transmission of the side collision load can be achieved.

The two bottom walls 81 d, 91 d adjoining to each other are located within a width in the front-rear direction of the pipe frame 5. With this feature, the side collision load can be effectively transmitted to the pipe frame 5 through the thick portion made up of the joined bottom walls 81 d, 91 d.

Furthermore, the center 5 b in the front-rear direction of the pipe frame 5 is located within a width in the front-rear direction of the thick portion made up of the joined bottom walls 81 d, 91 d. With this configuration, the load can be transmitted intensively to the center 5 b or therearound of the pipe frame 5 through the thick portion made up of the joined bottom walls 81 d, 91 d.

As shown in FIG. 4, a laterally inner end 91 b of the rear wall 91 is fixed to the side frame 4 by welding. To be more specific, as shown in FIG. 3( a), the laterally inner end 91 b of the rear wall 91 is joined to a closed section shaped portion made up of a rear portion 43, bent into an L-shape, of the side frame 4 and a left-side rear portion of the pipe frame 5. With this configuration, the side collision load transmitted from the rear wall 91 to a laterally inner side is received properly by the closed section shaped portion, and thus can be transmitted effectively to the pipe frame 5.

Furthermore, as shown in FIGS. 2, 3, the upper wall 92, outer wall 93 and lower wall 94 of the rear-side box-like member 9 is disposed over the upper wall 82, outer wall 83 and lower wall 84 of the front-side box-like member 8, and fixed to the walls 82-84, respectively by welding.

With this configuration, as shown in FIG. 3( b), the upper wall 72 of the bracket 7 has a stepped profile 72 a (providing an uneven shape) formed, at a position separate from the front and rear ends thereof, by overlapping the upper walls 82, 92 (two plate-like portions) of the respective box-like members 8, 9. With this configuration, a portion of the upper wall 72 substantially at the center thereof in the front-rear direction is formed as a thick portion by overlapping the upper walls 82, 92, and thus the rigidity of the upper wall 72 can be enhanced, so that a side collision load can be transmitted effectively.

Furthermore, since the stepped profile 72 a (providing an uneven shape) is formed in a position separate from the front and rear ends of the upper wall 72, the front and rear end corners of the upper wall 72 can be formed continuously in the left-right direction, so that the continuous corners can effectively transmit the load from outside to inside in the lateral direction.

Similarly, as shown in FIGS. 3( a), (c), the outer wall 73 and lower wall 74 of the bracket 7 also has stepped profiles 73 a, 74 a formed by overlapping the outer walls 83, 93 and the lower walls 84, 94, respectively, of the box-like members 8, 9. With this configuration, the rigidities of the outer wall 73 and the lower wall 74 as well can be enhanced, and the front and rear end corners of the lower wall 74 can be formed continuously in the left-right direction, so that the continuous corners can effectively transmit the load from outside to inside in the lateral direction.

The stepped profiles 72 a, 73 a, 74 a are formed continuously across the upper wall 72, outer wall 73 and lower wall 74 of the bracket 7 as a result of fitting the rear-side box-like member 9 on the front-side box-like member 8. With this configuration, the thick portion of the outer wall 73 is formed continuously to the thick portions of the upper wall 72 and the lower wall 74, and thus a side collision load received by the thick portion of the outer wall 73 can be transmitted effectively to the laterally inner side through the upper and lower continuous thick portions.

Advantageous effects of the vehicle seat according to the present embodiment as described above are summarized hereinafter.

Since a portion of the upper wall 72 and the lower wall 74 of the bracket 7 separate from their front and rear ends is configured to provide an uneven shape (stepped profiles 72 a, 74 a), the rigidity of the walls 72, 74 is enhanced; therefore, even if the wall thickness of the bracket 7 is thin, the walls 72, 74 are prevented from being buckled, so that a load can be transmitted effectively from outside toward inside in the lateral direction. Enhanced rigidity by this uneven shape allows the bracket 7 to be made thinner in wall thickness, and the vehicle seat to be made lighter in weight.

Since the uneven shape is not provided at the front and rear ends of the upper wall 72 and the lower wall 74, the front and rear end corners of the upper wall 72 and the lower wall 74 can be formed continuously in the lateral direction; therefore, these continuous corners serve to transmit a load effectively from outside to inside in the lateral direction.

Since the uneven shape is made of the stepped profile (stepped profile 72 a) provided by overlapping two walls (e.g., upper walls 82, 92), the overlapped portion of the two walls is rendered thicker, so that the rigidity can be enhanced.

Since the stepped profiles 72 a, 73 a, 74 a are provided continuously across the walls 72-74, i.e., the thicker portion of the outer wall 73 extends continuously to the upper wall 72 and the lower wall 74, a load received at the outer wall 73 can be transmitted effectively through the upper wall 72 and the lower wall 74 in a laterally inward direction.

Although the embodiment of the present invention has been described above, the present invention may be carried out into practice in appropriately modified configurations, as in the other embodiments described below.

In the above-described embodiment, the stepped profiles 72 a, 73 a, 74 a are provided continuously across the walls 72-74, but the present invention is not limited to this configuration; a stepped profile (uneven shape) provided merely in at least one of the upper wall and the lower wall may be advantageous. That is, for example, as shown in FIG. 5( a), a stepped profile 711 a may be provided only at an upper wall 711 of a bracket 710. In this configuration, as well, the rigidity of the upper wall 711 can be enhanced so that a load can be transmitted effectively.

Moreover, the stepped profile provided continuously from at least one of the upper wall and the lower wall to the outer wall may suffice. That is, for example, as shown in FIG. 5( b), stepped profiles 721 a, 722 a may be provided continuously from an upper wall 721 to an outer wall 722 of a bracket 720. In this configuration, as well, since the thicker portion of the outer wall 722 extends continuously to the upper wall 721, a load can be transmitted effectively from the outer wall 722 to the upper wall 721.

In the above-described embodiment, the stepped profile 72 a is adopted as an uneven shape, but the present invention is not limited to this configuration; for example, a recess or a protrusion may be adopted.

In the above-described embodiment, the base frame is configured to comprise the side frame 4 and the pipe frame 5, but the present invention is not limited to this configuration; for example, it may be configured with a side frame only or with a pipe frame only.

In the above-described embodiment, a cylindrical pipe frame 5 is adopted as an inner frame, but the present invention is not limited to this configuration; for example, a pipe frame having a polygonal cross section, a solid cylindrical member, or a solid prismatic member may be usable.

In the above-described embodiment, the force-receiving member is embodied in the bracket 7 composed of two box-like members 8, 9, but the present invention is not limited to this configuration; for example, a bracket formed by bending or drawing a single plate-like member, for example, as shown in FIG. 5( a), (b), may be usable.

In the above-described embodiment, the load transmission part is configured as an assembly of the lower frame 6 and the lower portion 51 of the pipe frame 5, but the present invention is not limited to this configuration. For example, in the above-described embodiment, the pipe frame 5 as the inner frame is formed integrally with the load transmission part (lower portion 51), but if the pipe frame is shaped like a letter U which opens toward downward, a separate frame connecting the lower end portions of the pipe frame may be provided as a load transmission part. Alternatively, if the lower portion 51 of the pipe frame 5 in the above-described embodiment is severed, with its midsection cut off, in two portions joined to the lower frame 6, the lower portions 51 extending halfway and the lower frame 6 may be configured as a load transmission part.

In the above-described embodiment, the bracket 7 and the pipe frame 5 are fixed together by welding, but the present invention is not limited to this configuration; for example, a bolt may be applied for fixing these members together.

In the above-described embodiment, the through hole 41 is configured to serve as an opening, but the present invention is not limited to this configuration; for example, the opening may be a hollow which opens to the front or to the rear.

In the above-described embodiment, part of the bracket 7 (i.e., extension portions 81 e) is passed through the opening (through holes 41), but the present invention is not limited to this configuration; part of the inner frame may be passed through the opening and fixed directly to the bracket.

In the above-described embodiment, the inner frame (pipe frame 5) is configured to have a shape with a closed section in its entirety, but the present invention is not limited to this configuration; it may be advantageous only if at least a portion of the inner frame to which the force-receiving member is fixed has a shape with a closed section. 

The invention claimed is:
 1. A vehicle seat comprising: a base frame which constitutes at least left and right lower portions of a seat back frame; a force-receiving member disposed adjacent to a left or right outer side of the base frame, and configured to receive a load from outside in a lateral direction; and a load transmission part configured to transmit the load from the force-receiving member to a side laterally opposite to that on which the force-receiving member is provided, wherein the force-receiving member includes an upper wall and a lower wall and has a shape with a closed cross section, and a portion of at least one of the upper wall and the lower wall separate from front and rear ends thereof provides an uneven shape, and wherein the uneven shape is of a stepped profile formed by overlapping two plate portions.
 2. The vehicle seat according to claim 1, wherein the stepped profile continuously formed from the at least one of the upper wall and lower wall to an outer wall located at a lateral outer side of the force-receiving member.
 3. The vehicle seat according to claim 2, wherein the force-receiving member is segmented in front and rear halves of box-shaped members which are fitted together, and configured such that the stepped profile is formed as a result of fitting the box-shaped members together, continuously across the upper wall, and the outer wall and the lower wall. 